Heating system for bathing unit

ABSTRACT

A control system suitable for use with a bathing unit system having a water receptacle is provided. The control system comprises a heating module, a power source and a controller in communication with the heating module and the power source. The power source includes an energy storage member for storing energy collected from a solar panel, and is operative for supplying power generated from solar energy to the heating module. The controller is operative for causing the power source to supply power to the heating module at least in part based on first information derived from a temperature of the water within the water receptacle and second information derived from a condition associated with the power source. The controller is further operative for selecting between a first power source and a second power source for supplying power to the heating module.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation claiming the right of priority under35 USC §120 based on U.S. patent application Ser. No. 11/415,229, whichwas filed on May 2, 2006 and which in turn claimed the benefit ofpriority under 35 USC §120 based on U.S. provisional patent applicationSer. No. 60/697,980 filed Jul. 12, 2005 by Michel Authier and nowabandoned. The contents of the above-mentioned patent applications areincorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to the field of bathing unit systems, suchas spas, whirlpools and hot tubs. More particularly, the presentinvention relates to bathing unit systems that are operative to heat thewater used therewith via power generated from solar energy.

BACKGROUND

Control systems for bathing unit systems such as spas, whirlpools, hottubs, bathtubs, therapeutic baths and swimming pools, are well known inthe art. Typically, such control systems are operative for controllingthe various functional components of the bathing unit systems. Thefunctional components can include water pumps, heating modules, filtersystems, air blowers, ozone generators, and lighting systems, amongothers.

In general, bathing unit control systems include a controller to whichthe various bathing unit components are connected. This controller isadapted to control the power supplied from a power source to each one ofthe various components. More specifically, in response to signalsreceived from a user of the bathing unit system, for example via acontrol panel, and/or in response to signals received from varioussensors, the controller will activate or de-activate the various bathingunit components by supplying power, or ceasing to supply power, to thosecomponents.

A function of the control system is to control the activation andde-activation of the heating module of the bathing unit system in orderto maintain the temperature of the water within the water receptaclewithin a desired temperature range. In the case of most bathing unitsystems the water temperature is maintained between 80 and 104 degreesFahrenheit.

Unlike bathtubs, the water contained within the water receptacles ofmany bathing unit systems is not drained each time the bathing unitsystem is used. As such, it is desirable to maintain the watertemperature within the desired temperature range at all times, even whenthe bathing unit system is not in use, such that the water does not haveto be reheated every time a user wishes to use the bathing unit system.Bathing unit systems are known to consume a significant amount of energyto maintain the water at a given temperature. This is especially truefor bathing unit systems that are located outdoors in cold climates.With energy consumption being a constant concern for governments andenergy producers, it is possible that in the near future the energyconsumption of bathing unit systems will be regulated in certain regionsof the world. Furthermore, the cost associated with heating the bathingunit, which the consumer bears, can be significant.

In order to conserve energy, most bathing unit systems include a coverthat fits over the water receptacle when the bathing unit system is notin use. These covers are generally insulated in order to prevent as muchheat loss from the water as possible. However, even with the insulatedcovers, the controller is still required to provide power to the heatingmodule in order to keep the water within the water receptacle within adesired temperature range.

One suggested manner of reducing the amount of energy consumption of apool system is described in U.S. Pat. No. 4,322,297 issued to Bajka onMar. 30, 1982. Bajka describes using the combination of solar waterheating and non-solar water heating for improving the efficiency of thepool system. More specifically, Bajka describes a controller that iscapable of preferentially using the solar water heating when possible. Adeficiency with the system described by Bajka lies in the manner inwhich the solar heating occurs. More specifically, the solar heatingconsists of solar panels through which water can flow. As the waterflows through the solar panels, it increases in temperature due to theenergy from the sun. The deficiency with this is that the solar heatingdescribed in Bajka is not functional in cold climates. For example, inthe wintertime, the water within the solar panels can freeze renderingthe system inoperable.

In light of the above, it can be seen that there exists a need in theindustry to provide a controller for a bathing system that alleviates atleast in part the deficiencies associated with the prior art.

SUMMARY

In accordance with a broad aspect, the present invention provides acontrol system suitable for use with a bathing unit system having awater receptacle. The control system comprises a heating module, a powersource and a controller in communication with the heating module and thepower source. The heating module has a body that defines a passagethrough which water can flow. The power source is operative forsupplying power generated from solar energy to the heating module. Thepower source includes an energy storage member adapted for establishingan electrical connection with a solar panel for storing energy collectedfrom the solar panel. The controller is operative for causing the powersource to supply power to the heating module at least in part on thebasis of first information derived from a temperature of the waterwithin the water receptacle and second information derived from acondition associated with the power source.

In accordance with another broad aspect, the invention provides acontrol system for a bathing unit system. The control system comprises afirst power source, a second power source and a controller incommunication with the first power source and the second power source.The second power source is suitable for supplying power derived fromsolar energy. The second power source includes an energy storage memberfor establishing an electrical connection with a solar panel for storingenergy collected from the solar panel. The controller is operative forselecting one of the first power source and the second power source forsupplying power to a heating module. The heating module includes a bodydefining a passage through which water can flow.

In accordance with yet another broad aspect, the invention provides abathing unit system that comprises a water receptacle, a heating modulehaving a body that defines a passage through which water can flow, apower source for supplying power generated from solar energy to theheating module and a controller that is in communication with theheating module and the power source. The power source includes an energystorage member adapted for establishing an electrical connection with asolar panel for storing energy collected from the solar panel. Thecontroller is operative for causing the power source to supply power tothe heating module at least in part on the basis of first informationderived from a temperature of the water within the water receptacle andsecond information derived from a condition associated to the powersource.

In accordance with yet another broad aspect, the present inventionprovides a control system suitable for use with a bathing unit systemthat has a water receptacle. The control system comprises heating meansfor heating water from the water receptacle, power source means forsupplying power generated from solar energy to the heating means andcontroller means for causing the power source means to supply power tothe heating means at least in part on the basis of first informationderived from a temperature of water within at least one of the waterreceptacle and a heating module and second information derived from acondition associated to the power source means. The power source meansinclude energy storage means for establishing an electrical connectionwith a solar panel for storing energy collected from the solar panel.

In accordance with yet another broad aspect, the present inventionprovides a control system suitable for use with a bathing unit systemhaving a water receptacle. The control system comprises a heating modulehaving a body defining a passage through which water can flow, a firstpower source, a second power source and a controller. The first powersource is operative for supplying power to the heating module and thesecond power source is operative for supplying power generated fromsolar energy to the heating module. The second power source including anenergy storage member for storing energy collected from the solar panel.The controller is in communication with the heating module, the firstpower source and the second power source, and is operative for derivingenergy consumption information associated with the use of the secondpower source.

These and other aspects and features of the present invention will nowbecome apparent to those of ordinary skill in the art upon review of thefollowing description of specific embodiments of the invention inconjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

A detailed description of the embodiments of the present invention isprovided herein below, by way of example only, with reference to theaccompanying drawings, in which:

FIG. 1 shows a bathing unit system in accordance with a firstnon-limiting example of implementation of the present invention;

FIG. 2 shows a block diagram of a controller in accordance with anon-limiting example of implementation of the present invention;

FIG. 3 is a flow chart of a process for selecting a power source forsupplying power to a heater module in the bathing unit system inaccordance with a non-limiting example of implementation of the presentinvention;

FIG. 4 shows a bathing unit system in accordance with a secondnon-limiting example of implementation of the present invention;

FIG. 5 shows a bathing unit system in accordance with a thirdnon-limiting example of implementation of the present invention;

FIG. 6A-6C are block diagrams of various embodiments of an output modulesuitable for use with a controller in accordance with specificnon-limiting examples of implementation of the present invention.

In the drawings, the embodiments of the invention are illustrated by wayof examples. It is to be expressly understood that the description anddrawings are only for the purpose of illustration and are an aid forunderstanding. They are not intended to be a definition of the limits ofthe invention.

DETAILED DESCRIPTION

Shown in FIG. 1 is a block diagram of a bathing unit system 10 inaccordance with a non-limiting example of implementation of the presentinvention. The term “bathing unit system”, as used for the purposes ofthe present description, refers to spas, whirlpools, hot tubs, bathtubs, therapeutic baths, swimming pools and any other type of bathingreceptacle that can be equipped with a control system for controllingvarious operational settings.

The Bathing Unit System 10

The bathing unit system 10 shown in FIG. 1 includes a water receptacle18 for holding water, a plurality of jets 20, a plurality of drains 22,a control system 24 and a plurality of bathing unit components. Thebathing unit components shown in FIG. 1 include water pumps 11 and 13, afilter 26 and an air blower 28 for delivering air bubbles to the waterreceptacle 18. It should be understood that the bathing unit system 10can include more or less bathing unit components without departing fromthe spirit of the invention. For example, the bathing unit system 10could also include an ozonator, lighting components for lighting up thewater in the water receptacle 18, multimedia components such as a CD/DVDplayer and/or any other components suitable for use in a bathing unitsystem 10.

During the course of normal operation, water flows from the waterreceptacle 18 through one or more drains 22 and is pumped by water pump13 through the circulation piping 33 and the heating module 30 where thewater is heated. The heated water re-enters the water receptacle 18through one or more jets 20. This cycle of water leaving the waterreceptacle 18 through one or more drains 22, passing through the heatingmodule 30 and re-entering the water receptacle 18 through one or morejets 20 is repeated continuously while the water pump 13 is active.

In addition, the water from the water receptacle 18 passes through afiltration cycle wherein the water flows through one or more drains 22and is pumped by water pump 11 through a filter 26. After having beenfiltered, the water then re-enters the water receptacle 18 through oneor more jets 20. This cycle of water leaving the water receptacle 18through drains 22, passing through the filter 26 and re-entering thewater receptacle 18 through jets 20 is repeated continuously while thewater pump 11 is active. This cycle keeps the water clean fromparticulate impurities.

The Control System 24

As mentioned above, the bathing unit system 10 includes a control system24 for controlling the temperature of the water within the waterreceptacle 18 and activating and deactivating the various bathing unitcomponents of the bathing unit system 10. In the non-limiting embodimentshown in FIG. 1, the control system 24 includes a heating module 30, acontrol panel 32, a controller 34, an auxiliary controller 36(optional), a first power source 38 and a second power source 40.

Heating Module 30

In accordance with a non-limiting example of implementation, the heatingmodule 30 includes a body defining a passage through which water canflow as well as a heating element for transferring heat to the waterthat flows through the passage. The heating element can include anelectric heater or a gas heater without departing from the spirit of theinvention. Alternatively, the heating element can include heatingsurface components positioned on the outer and/or inner surfaces of thebody of the heating module. It is to be understood that the water flowpassage and heating element can take various respective configurationswithout departing from the spirit and scope of the present invention. Aswill be described in more detail below, regardless of the type ofheating element employed by the heating module 30, the heating module 30is operative for being powered by one of the first power source 38 andthe second power source 40.

The body of the heating module 30 can be formed of a conductive materialor an electrically non-conductive material. The expression “electricallynon-conductive material” refers to a class of materials havingsubstantially low electrical conductivity properties such as plastics,elastomers, ceramics, and selected composite materials. Moreover, thebody of the heating module 30 may include a plurality of electricallynon-conductive portions, or may be made entirely of such electricallynon-conductive materials. In a specific practical implementation, thebody of the heating module 30 is formed of an electricallynon-conductive portion, but comprises one or more conductive portionsfor providing an electrical path between the water in the heating module30 and ground.

Control Panel 32

The control panel 32 is typically in the form of a user interface thatallows a user to enter command signals for controlling the variousoperational settings of the bathing unit system 10. The control panel 32can include buttons, levers or any other device known in the art forenabling a user to enter input commands for controlling the variousoperational settings of the bathing unit system 10. The user can alsouse the control panel 32 for entering input commands indicative of whichof the first and second power source 38 and 40 should be used to powerthe heating module 30.

In a non-limiting embodiment, the control panel 32 can include a screenfor conveying information to a user, such as the water temperature, theambient air temperature and the time, among other possibilities.

Some non-limiting examples of the operational settings of the bathingunit system 10 that can be controlled by the control panel 32 includeon/off settings, temperature control settings, jet control settings,lighting settings, etc. In a non-limiting example of implementation, thebathing unit system 10 includes entertainment and/or multimediacomponents, such that the operational settings of the bathing unit mayalso include audio settings and video settings, amongst others.Consequently, the expression “operational settings”, for the purpose ofthe present invention, is intended to cover operational settings for anysuitable component that is part of the bathing unit system 10.

First Power Source 38

In accordance with the present invention, the first power source 38 is a“traditional” power source such as a standard electric power source or agas powered source. For the purposes of the present invention, the term“traditional” power source refers to power sources that supply powergenerated from commercial energy providers and for which the user mustpay a fee typically based on consumption. The first power source 38 isoperative to supply the controller 34 with any conventional powerservice suitable for residential or commercial use. For example, thefirst power source 38 can supply 240 volts (V) AC to the controller 34via service wiring 31. In an alternative non-limiting example ofimplementation, the power source 38 can supply 120 V AC to thecontroller 34 via service wiring 31. In a further alternativenon-limiting example of implementation, the power source 38 can supply120 V and 240 V AC to the controller 34 via service wiring 31. It is tobe appreciated that other voltage supply values or voltage supplycombinations are possible without detracting from the spirit and scopeof the invention. For example the voltage supply values may be differentdepending on geographical location.

Second Power Source 40

Specific to the present invention, the second power source 40 isoperative for supplying power generated from solar energy. The secondpower source 40 includes one or more energy storage members for storingenergy collected from solar energy. In the non-limiting example ofimplementation shown, the one or more energy storage members are in theform of batteries 41. The batteries 41 are adapted for establishing anelectrical connection with one or more solar panels 44 such that theyare able to store the energy collected from the solar panels 44. Abattery charger 42 is connected between the batteries 41 and the solarpanels 44 and is operative for converting the electrical energy from thesolar panels 44 into an electric current to charge the batteries 41.Since power from the batteries 41 may not be needed at all times, thecurrent used to charge the batteries is passed through a regulationcircuit so as to regulate the current stored within the batteries 41. Ina non-limiting example of implementation, the regulation circuit isincluded within the battery charger 42. However, it should be understoodthat the regulation circuit could be separate from the battery charger42 and could have been represented by an additional block within FIG. 1.

In a non-limiting example of implementation, solar panels including aphotovoltaic module supplied by Evergreen Solar, GmbH are suitable foruse with the bathing unit system 10. It will be appreciated that oncethe initial cost of purchasing the solar panels has been made, the solarpanels will generate energy essentially free of charge. As such, bypowering the heating module 30 of the bathing unit system 10 via energygenerated from the solar panels 44, the operating costs of the bathingunit system 10 can be greatly reduced.

Controller 34

The controller 34 is operative for controlling theactivation/de-activation of the various bathing unit components and ofthe heating module 30. This can be done on the basis of commands enteredby the user via the control panel 32, or on the basis of control signalsreceived from various sensors.

In the non-limiting embodiment shown, the controller 34 is incommunication a temperature sensor 72 that is operative for taking atemperature measurement of the water within the water receptacle 18. Inaddition, the controller 34 is in communication with a temperaturesensor 74 that is operative for taking a temperature measurement of thewater within the circulation piping 33 of the heating module 30.Although not shown, the bathing unit system 10 can also include othersensors that are operative for monitoring various operational conditionsof the bathing unit system 10. For example, the bathing unit system 10may include liquid level sensors for monitoring the water level atvarious locations in the bathing unit system 10. Other sensors that aresuitable for use within a bathing unit system 10 can also be includedwithout departing from the spirit of the invention.

As will be described in more detail below, the controller 34 isoperative for selecting between the first power source 38 and the secondpower source 40 for supplying power to the heating module 30. It will beappreciated that the use of the second power source 40, namely the solarcharged batteries 41 in this non-limiting example, will reduce theamount of energy required from the first power source 38, and therebyreduce the energy costs associated with operating the bathing unitsystem 10. The manner in which the controller 34 selects between thefirst power source 38 and the second power source 40 will be describedin more detail further on in the specification.

Auxiliary Controller 36

In the non-limiting embodiment shown in FIG. 1, the control system 24further includes an auxiliary controller 36. The auxiliary controller 36is in communication with both the controller 34 and the second powersource 40, such that it is operative for causing the second power source40 to supply power to the heating module 30 on the basis of commandsreceived from the controller 34. Although the auxiliary controller isrepresented by block 36 in FIG. 1, it should be appreciated that, incertain embodiments, the functionality of the auxiliary controller 36can be included within the controller 34.

Supplying Power to the Heating Module 30

For most bathing unit systems 10, the temperature of the water containedwithin the water receptacle 18 is maintained within a desiredtemperature range at all times, including those times when the bathingunit system 10 is not in use. In this manner the water contained withinwater receptacle 18 does not need to be re-heated every time a batherwishes to use the bathing unit system 10. A common temperature range forthe water within water receptacles 18 of most bathing unit systems 10 issomewhere between 80 and 104 degrees Fahrenheit. Since this temperaturerange is quite high, it will be appreciated that if the watertemperature was not kept within proximity to this desired temperaturerange at all times, it would take a long time to reheat the water everytime a user wanted to use the bathing unit system 10.

As mentioned above, controller 34 monitors the conditions of the waterand maintains the water temperature in the water receptacle 18 withinthe desired temperature range. Shown in FIG. 2 is a more detaileddiagram of a controller 34 in accordance with a non-limiting embodimentof the present invention. In the embodiment shown, the controller 34includes a processing unit 50 and a memory unit 56. The processing unit50 includes a diagnostic unit 52 and a control unit 54.

The desired temperature range of the water within the water receptacle18 is generally calculated on the basis of a desired water temperature.Typically, the desired temperature range is calculated to be within afew degrees of the desired water temperature. For example, the desiredtemperature range may be ±1° C. from the desired water temperature. Thedesired water temperature can be a predefined temperature stored inmemory 56, or a temperature that is entered by a bather via the controlpanel 32. In the case where the desired water temperature is entered bya bather, it is also stored in the memory unit 56. Preferably, thedesired water temperature is between 38 and 41° C. For the sake ofexample, let us assume that a bather entered the desired temperature of40° C. As such, the desired temperature range might be from 39° C. to41° C.

It should be understood that the controller 34 may be operative tomaintain the water within the water receptacle 18 within differentdesired temperature ranges depending on different conditions. Forexample, there may be a first desired temperature range when the bathingunit system is in use and a second desired temperature range when thebathing unit system is not in use. In such a case, the second desiredtemperature range may be lower than the first desired temperature range.For example, the desired temperature range when the bathing unit systemis in use may be between 39-41° C., and the desired temperature rangewhen the bathing unit system is not in use may be between 37-39° C. Inthis manner, when the bathing unit system 10 is not in use, the waterwithin the water receptacle 18 will remain warm enough so that it can bequickly heated to the desired “in use” temperature, but will not requireas much energy as if the water were kept within the higher temperaturerange at all times.

It should be appreciated that different temperature ranges may also beused in other circumstances as well. For example, there may be a certaindesired temperature range for summer use, and a different desiredtemperature range for winter use. Likewise, there may be a certaindesired temperature range for day time use, and a different desiredtemperature range for night time use. Furthermore, the ambient airtemperature may determine the desired temperature range so that therange is set differently on a very hot day than on a cooler day. Thesetemperature ranges may be preset by the controller 34 manufacturer ormay be programmable by a user of the bathing unit system.

These different temperature ranges, as well as program instructions forinstructing the control unit 54 when to use these different temperatureranges, may be stored in the memory 56 of the controller 34.

A non-limiting example of a process used by the controller 34 formaintaining the water temperature within the water receptacle 18 withina desired temperature range will now be described in more detail.

For the sake of simplicity, let us assume that the process begins whenthe heating module 30 is in the de-activated state. It should beappreciated, however, that the process that is about to be described isperformed on a cyclical basis, and as such there is no specific startingpoint.

While the heating module 30 is in the deactivated state, the controller34 is operative for monitoring the temperature of the water within thewater receptacle 18. This can be done by obtaining readings from thetemperature sensor 72 located within the water receptacle 18, or in thecase where there is no temperature sensor within the water receptacle18, this can be done by obtaining readings from a temperature sensor 74located within the circulation piping 33 of the heating module 30.Preferably, in the case where the temperature reading is taken from thetemperature sensor 74, the controller 34 causes the water pump 13 tocirculate water from the water receptacle 18 through the circulationpiping 33 prior to taking a temperature reading. This ensures that thereading of the temperature sensor 74 is in fact indicative of thetemperature of the water within the water receptacle 18. Morespecifically, once the water pump 13 has been de-active for a period oftime, the water in the circulation piping 33 will often be at adifferent temperature than the water in the water receptacle 18. Thisdifference in temperature may be caused by the water receptacle 18 beingpositioned in direct sunlight and the circulation piping 33 beingpositioned under the water receptacle 18 in the shade. Therefore, inorder to ensure that the reading taken by temperature 74 is in factindicative of the temperature of the water within the water receptacle18, the water is circulated between the water receptacle 18 and theheating module 30 for a period of time prior to taking a temperaturereading. A method of controlling the activation/deactivation of thewater pump 13 is described in co-pending U.S. patent application Ser.No. 10/768,062, filed on Feb. 2, 2004 in the name of Christian Brochu etal. the contents of which are incorporated herein by reference.

It should be appreciated that although temperature sensor 74 is shown asbeing located within the circulation piping 33, the temperature sensor74 could also be positioned in other locations, such as within the bodyof the heating module 30, without detracting from the spirit of theinvention.

It should also be appreciated that although FIG. 1 shows a bathing unitsystem 10 that includes both temperature sensors 72 and 74, it is withinthe scope of the present invention for the bathing unit system 10 toinclude only one of temperature sensors 72 and 74.

With reference to FIG. 2, the diagnostic unit 52 of the controller 34obtains the temperature readings from one or both of sensors 72 and 74.These temperature readings are taken periodically and are processed atleast in part on the basis of the desired temperature range stored inmemory 56 in order to determine when the water temperature within thewater receptacle 18 has approached, or descended below, the lower limitof the desired temperature range. Once the temperature has approached ordescended below the lower limit of the temperature range, the diagnosticunit 52 sends a message to the control unit 54, such that the controlunit 54 can causes the heating module 30 to be activated. The heatingmodule 30 is activated when it is supplied power from one of the firstpower source 38 and the second power source 40. The manner in which thecontrol unit 54 selects between the first power source 38 and the secondpower source 40 will be described in more detail later on in thedescription.

Once the heating module 30 is activated, the water within the waterreceptacle 18 begins to heat up. During this time, the diagnostic unit52 of the controller 34 continues to obtain temperature readings fromone or both of the temperature sensors 72 and 74. Again, thesetemperature readings are processed at least in part on the basis of thedesired temperature range stored in memory 56. When the diagnostic unit52 determines that the water temperature has reached or exceeded theupper level of the desired temperature range, the diagnostic unit 52sends a message to the control unit 54 for causing the heating module 30to be deactivated. While the heating module is deactivated, the water inthe water receptacle 18 begins to cool down. Then, as described above,the diagnostic unit 52 obtains temperature readings from one or both oftemperature sensors 72 and 74 for determining when the temperature hasreached the lower limit of the temperature range. Then the cycle beginsagain. This process is repeated continuously in order to keep the watertemperature within the water receptacle 18 within the desiredtemperature range.

Although not shown in FIG. 2, the controller 34 is in communication withactuators for causing the water pump 13 and the heating module 30 to beactivated and deactivated. Some non-limiting examples of actuators thatcan be used for this purpose include relays, switches and TRIACs.

Selecting Between the First Power Source and the Second Power Source

The manner in which the controller 34 selects between the first powersource 38 and the second power source 40 will now be described in moredetail with reference to the flow chart shown in FIG. 3.

Firstly, at step 100, the controller 34 determines whether the waterwithin the water receptacle 18 needs to be heated, and as such whetherthe heating module 30 needs to be activated. This is determined usingthe process described above, wherein the heating module 30 is activatedwhen the water temperature within the heating module 30 has approached,or descended below, the lower limit of the desired temperature range.Until the lower limit of the temperature range has been approached noaction is taken.

Once the temperature of the water within the water receptacle 18 hasapproached or descended below the lower limit of the temperature range,the control unit 54 of the controller 34 determines that the water needsto be heated and that the heating module 30 should be activated. Inorder to cause the heating module 30 to be activated, the controller 34must allow power to be supplied to the heating module 30. As such, atstep 102, the control unit 54 selects one of the first power source 38and the second power source 40 to supply power to the heating module 30.This selection can be made on the basis of program instructions storedin the memory unit 56, or on the basis of a command entered by a user ofthe bathing unit system.

For example, a user may enter a command via the control panel 32indicative that only the first power source 38 is to be used untilfurther notice. In such a case, at step 102 the control unit 54 willselect the first power source 38. It should be understood that the usercould also enter a signal via the control panel 32 indicative that onlythe second power source 40 is to be used. In such as case, at step 102,the control unit 54 will select the second power source 38.

Alternatively, the control unit 54 can select one of the first powersource 38 and the second power source 40 on the basis of programinstructions stored within the memory unit 56 of the controller 34. Theprogram instructions can cause the control unit 54 to select one of thefirst power source 38 and the second power source 40 on the basis ofmany different some pre-programmed criteria.

In accordance with a first non-limiting example, the programinstructions may cause the control unit 54 to select the second powersource 40 at all times. As such, whenever the control unit 54 determinesthat the heating module 30 should be activated, the control unit 54 willselect the second power source 40.

In accordance with a second non-limiting example, the programinstructions may cause the control unit 54 to intermittently selectbetween the first power source 38 and the second power source 40 on thebasis of time. More specifically, the program instructions may cause thecontrol unit 54 to select the first power source 38 for a first lengthof time, and then select the second power source for a second length oftime. For example, it may be desirable to use the first power source 38for two hours, and then use the second power source 40 for two hours.The control unit 54 may switch back and forth between the two powersources in this manner. Alternatively, the program instructions maycause the control unit 54 to alternate between the two power sourceseach time a power source needs to be used. As such, the first powersource 38 will be selected the first time power needs to be supplied tothe heating module 30, and then the second power source 40 will beselected for second time power needs to be supplied to the heatingmodule. The control unit 54 may switch back and forth in this manner. Inyet another alternative example, the program instructions may cause thecontrol unit 54 to select between the two power sources in a random-likemanner.

In yet another alternative example, the program instructions mayinstruct the control unit 54 to select between the two power sources onthe basis of the functioning of the bathing unit system 10. For example,the program instructions may cause the control unit 54 to select thefirst power source 38 when the bathing unit system 10 is being used by abather, and the second power source 40 when the bathing unit system 10is not in use. In this manner, the second power source would be used asmuch as possible when the bathing unit system is not in use. There aremany ways that the control unit 54 can detect that the bathing unitsystem 10 is in use. For example, the control unit 54 can detect thatthe system is in use when a user activates a “start” button on thecontrol panel 32. Alternatively, the bathing unit system may include asensor that detects when the bathing unit cover is off. As such, whenthe control unit 54 detects that the cover is off, the bathing unitsystem detects that the system is in use. Many other manners ofdetecting that the bathing unit system 10 is in use are included withinthe scope of the present application.

It should be appreciate that the program instructions can cause thecontrol unit 54 to select between the first power source 38 and thesecond power source 40 on the basis of a variety of different criteria,not all of which have been described above. The present invention is notlimited to the manner in which the control unit 54 selects between thefirst and second power sources.

Referring back to FIG. 3, in the case where the control unit 54 selectsthe first power source 38, the process proceeds to step 104, wherein thecontrol unit 54 causes the first power source 38 to supply power to theheating module 30.

However, in the case where the control unit 54 selects the second powersource 40, the process proceeds to step 106, wherein the controller 34determines whether the second power source 40 can in fact be used tosupply power to the heating module 30. Under certain conditions whichwill be described below, it is not always possible for the second powersource 40 to supply power to the heating module 30.

In accordance with the present invention, the controller 34 is operativefor causing the second power source 40 to supply power to the heatingmodule 30 on the basis of first information derived from a temperatureof the water within the water receptacle 18 and on the basis of secondinformation derived from a condition associated with the second powersource 40. In accordance with a non-limiting example of implementation,the first information includes temperature measurements obtained fromone or both of the temperature sensors 72 and 74. This information isreceived at the diagnostic unit 52.

In a first non-limiting example of implementation, the diagnostic unit52 processes this first information against the desired temperaturerange in order to confirm that the water temperature in the waterreceptacle 18 has approached or descended below the lower limit of thedesired temperature range. In the case where it has approached ordescended below the desired temperature range, the diagnostic unit 52confirms that it is appropriate to supply power from the second powersource 40. It should be appreciated that this processing operation mayin fact have taken place at step 100, and as such is not repeated againat this stage.

In an alternative non-limiting example of implementation, the diagnosticunit 52 processes the first information at least in part on the basis ofminimum temperature information stored in the memory unit 56. Theminimum temperature information is operative for enabling the diagnosticunit 54 to determine whether the water temperature is too low to beheated via power supplied by the second power source 40. If the watertemperature is too low, the second power source 40 may not be sufficientfor supplying enough power to raise the temperature of the water, or toraise the temperature of the water fast enough. In such a situation, thediagnostic unit 52 may determine that it is not appropriate to use thesecond power source 40. However, if the water temperature is above theminimum temperature information, the diagnostic unit 52 will determinethat the second power source 40 can be used.

The second information is also received at the diagnostic unit 52through the auxiliary controller 36. It should be appreciated that inthe case where there is no auxiliary controller 36, the diagnostic unit52 obtains the second information directly from the battery or batteries41. In accordance with a non-limiting example of implementation, thesecond information is indicative of the voltage of the battery orbatteries 41.

The diagnostic unit 52 is operative to process this information todetermine whether the battery or batteries 41 have sufficient voltage topower the heating module 30. It should be appreciated that, instead ofreceiving a signal indicative of the voltage of the battery or batteries41, the auxiliary controller 36 may simply issue a signal to thediagnostic unit 52 indicative that there is, or is not, sufficientvoltage in the batteries 41 for heating the water. At least in part onthe basis of this second information, the diagnostic unit 52 is able todetermine whether or not the second power source 40 can be used tosupply power to the heating module 30.

Therefore, the diagnostic unit 52 is operative for processing this firstinformation and the second information in order to determine if thesecondary power source 40 can be used to supply power to the heatingmodule 30.

In a first non-limiting example of implementation, in the case where thefirst information and the second information are indicative that it isinappropriate to use the second power source 40, the control unit 54proceeds to step 108 and defaults to causing the first power source 38to supply power to the heating module 30.

Alternatively, in the case where the first information and the secondinformation are indicative that it is inappropriate to use the secondpower source 40, instead of defaulting to the first power source 38, thecontrol unit 54 will do nothing, meaning that neither power source willprovide power to the heating module 30. This may be the case if a userhas entered a command indicative that only the second power source 40 isto supply power to the heating module 30 under all conditions. As such,if the second power source 40 is unable to provide power to the heatingmodule 30, there will be no power supplied to the heating module 30.

In the case where both the first information and the second informationare indicative that the second power source 40 can be used, thediagnostic unit 52 issues a command to the control unit 54 indicativethat the second power source 40 should be used. As such, at step 110,the control unit 54 either directly, or indirectly via the auxiliarycontroller 36, causes the second power source 40 to supply power to theheating module 30.

In a non-limiting implementation, when the control unit 54 proceeds tostep 110, the diagnostic unit 52 continues to obtain information fromone or both of temperature sensors 72 and 74 associated with thetemperature of the water in the water receptacle 18. If the watertemperature within the water receptacle 18 decreases, or stays the samewhile the secondary power source 40 is supplying power to the heatingmodule 40, the diagnostic unit 52 returns to step 106 and determinesthat the second power source 40 is insufficient to do the job. In suchcases, the controller 34 will proceed to step 108 wherein the controlunit 54 defaults to causing the first power supply 38 to supply power tothe heating module 30.

As mentioned above, the manner in which the controller 34 selects to usethe second power source 40 can depend on a variety of differentcriteria. However, once the controller 34 has determined that the secondpower source 40 should be used, the controller 34 then determines on thebasis of the first information and the second information describedabove whether the second power source 40 can in fact be used. When thefirst and second information are indicative that the second power source40 cannot or should not be used, the controller 34 will eitherautomatically default to using the first power source 38 to supply powerto the heating module 30, or will prevent any power from being suppliedto the heating module 30.

Although the flowchart of FIG. 3 shows step 106 as being after step 102,it should be appreciated that these two steps can be performedsimultaneously, instead of one after the other. As such, thedetermination of whether the second power source 40 can be used occursat the same time as the control unit 54 is performing the selection ofthe first and second power sources 38, 40.

Alternatively, step 106 can be performed prior to step 102, such thatthe control unit 54 knows whether the second power source 40 can be usedprior to selecting between the first and second power sources 38, 40. Insuch a case, the determination of whether the second power source 40 canbe used will affect the selection between the first and second powersource 38, 40. For example, in the case where the control unit 54determines that the second power source 40 cannot be used, then at step102 the control unit 54 will select the first power source 38 (providedthat the user has not indicated that only the second power source 40 canbe used).

Optionally, in the case where the second power source 40 is being usedto supply power to the heating module 40, the second power source 40 mayalso supply power to the water pump 13 and, optionally, the otherbathing unit components.

In accordance with a non-limiting example of implementation, in order tobe able to supply power to the heating module 30 via a selected one ofthe first power source 38 and the second power source 40, the controller34 is in communication with a first actuator associated with the firstpower source 38 and a second actuator associated with the second powersource 40. Thus, depending on which power source is selected by thecontroller 34, the controller 34 causes the actuator associated with theselected power source to be activated, such that power from that powersource can pass to the heating module 30.

In yet another embodiment, both the first power source 38 and the secondpower source 40 can be used simultaneously to supply power to theheating module 30. This may be desirable in the case where the secondpower source 40 is not able to supply sufficient power to the heatingmodule 30 on its own, but it is not desirable to default to the firstpower source 38 altogether. As such, the second power source 40 cansupply what power it is able to, and the first power source 38 cansupply the remaining power required. In this way the costs of operatingthe bathing unit system are less than if the control unit 54 simplydefaults to using the first power source 38.

In the embodiment described above with respect to FIG. 1, the controlsystem 24 includes only a single heating module 30. Although only oneheating module 30 is shown, it should appreciated that more than oneheating module can be included within the scope of the presentinvention.

Some non-limiting examples of alternative embodiments of the controlsystem 24 will now be described in more detail with respect to FIGS. 4and 5.

Bathing Unit System 60

Shown in FIG. 4 is a bathing unit system 60 in accordance with a seconda non-limiting example of implementation of the present invention. Thecomponents of the bathing unit system 60 that are the same as thosedescribed above with respect to bathing unit system 10 have beenrepresented using the same reference numbers.

Bathing unit system 60 comprises a control system 62 that includes acontroller 34, a control panel 32, an auxiliary controller 36(optional), a first power source 38 and a second power source 40.However, as opposed to the control system 34 described above, thecontrol system 62 shown in FIG. 4 includes a primary heating module 64and an auxiliary heating module 66. The primary heating module 64comprises separate circulation piping 63 from the circulation piping 65associated with auxiliary heating module 66. As such, the primaryheating module 64 is connected to a water pump 68 for causing water toflow through heating module 64. Likewise, the auxiliary heating module66 is connected to a water pump 70 for causing water to flow through theheating module 66.

In accordance with this embodiment, the first power source 38 isassociated with the primary heating module 64. As such, the second powersource is associated with the auxiliary heating module 66. Thecontroller 34 is in communication with each of the first power source 38and the second power source 40 and is operative for causing the firstheating module 64 and the auxiliary heating module 66 to be activated.

The manner in which the controller 34 maintains the water temperaturewithin the water receptacle 18 is the same as that described above. Morespecifically, the controller 34 is in communication with one or both oftemperature sensors 72 and 74 for obtaining the temperature of the waterwithin the water receptacle 18. As such, when the water temperatureapproaches or descends below a desired temperature range, the controllercauses one of the heating modules 64 or 66 to be activated.

Likewise, the manner in which the controller 34 selects which powersource to be used, and determines whether the second power source can beused, are the same as those described above with respect to FIG. 3. Adifference between the bathing unit system 10 described above withrespect to FIG. 1, and the bathing unit system 60 shown in FIG. 4, isthat when the controller 34 determines that power is to be supplied bythe first power source 38, it is the primary heating module 64 and thewater pump 68 that are activated. Similarly, when the controller 34determines that power is to be supplied by the second power source 40,it is the auxiliary heating module 66 and the water pump 70 that areactivated.

In a non-limiting example of implementation, the auxiliary heatingmodule 66 may be designed to require less power than the heating module64, such that it is easier for the second power source 40 to power. Forexample, the auxiliary heating module 66 may include a heating element(not shown) that emits less heat than a heating element of the primaryheating module 64, but that does not require as much power from a powersource in order to be activated. This set-up may be desirable when thesecond power source 40 is unable to supply sufficient power foractivating the heating element of the primary heating module 64.

Bathing Unit System 80

Shown in FIG. 5 is a bathing unit system 80 in accordance with a thirdnon-limiting example of implementation of the present invention. Thecomponents of the bathing unit system 80 that are the same as thosedescribed above with respect to bathing unit system 10 shown in FIG. 1have been represented using the same reference numbers.

Bathing unit system 80 comprises a control system 72 that includes acontroller 34, a control panel 32, an auxiliary controller 36(optional), a first power source 38 and a second power source 40. In theexample depicted the second power source 40 includes one or more solarpowered batteries. The control system 72 shown in FIG. 5 includes aprimary heating module 76 and an auxiliary heating module 78. Theprimary heating module 76 and the auxiliary heating module 78 share thesame circulation piping 77, but each include separate water pumps. Theprimary heating module 76 is connected to a water pump 82 for causingwater to flow through heating module 76, and the auxiliary heatingmodule 78 is connected to a water pump 84 for causing water to flowthrough the heating module 78. It should be appreciated that in analternative embodiment, there may be a single water pump for circulatingwater through both the heating module 76 and the auxiliary heatingmodule 78 at the same time.

The manner in which the controller 34 maintains the water temperaturewithin the water receptacle 18 is the same as described above. Morespecifically, the controller 34 is in communication with one or both oftemperature sensors 72 and 74 for obtaining the temperature of the waterwithin the water receptacle 18. As such, when the water temperatureapproaches or descends below a desired temperature range, the controller34 causes one of the heating modules 76 or 78 to be activated.

Likewise, the manner in which the controller 34 selects which powersource to be used, and determines whether the second power source 40 canbe used, are the same as those described above with respect to FIG. 3. Adifference between the bathing unit system 10 described above, and thebathing unit system 80 shown in FIG. 5, is that when the controller 34determines that power is to be supplied by the first power source 38, itis the primary heating module 76 and the water pump 82 that areactivated. Similarly, when the controller 34 determines that power is tobe supplied by the second power source 40, it is the auxiliary heatingmodule 78 and the water pump 84 that are activated. Although the heatingmodule 76 and the auxiliary heating module 78 have been shown as beingconnected in a parallel type configuration in FIG. 5, the heating module76 and the auxiliary heating module 78 may also be connected in seriesin alternative implementations without detracting from the spirit of theinvention.

Monitoring the use of the Second Power Source

In a non-limiting example of implementation, the control unit 54 of thecontroller 34 is operative for deriving energy consumption informationconveying information associated with the use of the second power source40.

The energy consumption information derived by the control unit 54 caninclude information about the amount of time the second power source 40is in use, the amount of time the second power source is in use comparedwith the first power source 38, the cost savings associated with the useof the second power source, and any other statistics associated with theuse of the second power source 40. The information derived by thecontrol unit 54 can, for example, be expressed in hours, percentagesand/or dollars. As such, this information can convey to the user thatthe second power source is working properly, and, optionally, that it isreducing the costs associated with operating the bathing unit system 10.Optionally still, this information can be used to monitor the amount ofpower being consumed such as to automatically adjust the usage of thepower sources depending on certain desired criteria.

Some non-limiting examples of information that could be conveyed to theuser will be described below. In a first non-limiting example, theoutput conveyed to the user may include the amount of time the secondpower source was in use over the course of a week in comparison to thefirst power source. For example, the output may state:

-   -   Power Breakdown For The Past 7 Days        -   Electric Power: 24 hrs        -   Solar Power: 60 hrs

Alternatively, this information can be given in percentages, such as:

-   -   Breakdown of Power Consumption For the Past 7 Days:        -   Electric Power 30%>        -   Solar Power 70%

In a second non-limiting example, the information conveyed to the usermay be the cost savings associated with the use of the second powersource. For example, if it is known that the heating module requires 5.5KW*hr of energy, and it is known that the second power source was in usefor 60 hours over the course of a week, then it can be calculated thatthe second power source supplied 330 KW·hrs of power over the course ofthat week. This is essentially 330 KW·hr that would otherwise have hadto be supplied by the first power source. Let us assume that the cost ofa KW·hr of power supplied by the first power source is 10 cents. Assuch, the cost savings can be calculated via the following formula:

Cost savings=(KW·hr supplied by second power source)*($/KW·hr of powersupplied by the first power source)

In the case of the example outlined above, the costs savings for thatweek would be: (330 KW·hr)*(0.10$/KW·hr)=$33

As such, the output could indicate:

-   -   >Cost Savings for the last 7 days=$33

Once this energy consumption information has been derived, it can becommunicated to a user via an output module 88. In the specificnon-limiting examples of implementation shown in FIGS. 6A through 6C,the bathing unit system 10 includes an output module 88 in communicationwith the controller 34. It is the output module 88 that is adapted forconveying the energy consumption information to the user.

In the specific example of implementation shown in FIG. 6A, the outputmodule 88 is a part of the control panel 32, and may include, forexample, a visual display element and/or an audio element torespectively convey to a human operator visual and/or audibleinformation indicative of the data associated with the use of the secondpower source. The visual display element could be, for instance, aliquid-crystal display (LCD) or one or more light-emitting diodes(LEDs). As such, the energy consumption information may be conveyed to auser in a visual format by displaying a message on a screen of theoutput module 88, or by turning ON (or OFF) an appropriate LED orcausing an appropriate LED to blink.

In another non-limiting embodiment shown in FIG. 6B, the output module88 can be included within the housing of the controller 34 such that itis concealed from the user under typical operation. For example, theoutput module may simply be a dial that counts the number of hours thesecond power source 40 is in use. In such an embodiment, the outputmodule 88 can be accessed by the user when the user desires to obtainthe energy consumption information such as once a year for example.

In an alternative embodiment not shown in the drawings, the outputmodule 88 is positioned remotely from both the control panel 32 and thecontroller 34. In such a case, the output module 88 may be positionedanywhere such that the information may be displayed anywhere in thebathing unit system 10 or in the proximity of the bathing unit system10. For example, the energy consumption information may be displayed ona dedicated user interface, on a user operable console of the bathingunit system 10, on an external direct wire device or on a devicepositioned remotely from the controller 30. Depending on where theoutput module 88 is positioned, it should be understood that thecontroller 34 can be in either wireless or wire-line communication withthe output module 88.

In another non-limiting embodiment shown in FIG. 6C, the output module88 includes a transmitter or transceiver 89 operative to transmit asignal conveying information to a user indicative of the energyconsumption information. The transmitter/transceiver 89 is operative totransmit the information over either one of a wireless link, such as aradio frequency (RF) link or infra-red (IR) link, or alternatively overa wire-line link. The transmitter/transceiver 89 communicates with anauxiliary I/O device 90, such as a laptop, a PDA or a cellular phone toconvey information indicative of the error condition to a humanoperator. In a specific non-limiting implementation, the auxiliary I/Odevice 90 is in the form of a dedicated display module suitable to bepositioned inside a house and in wireless communication with thetransmitter/transceiver 89 of output module 88.

In yet another alternative embodiment, instead of conveying the energyconsumption information to a user in an audio or visual format via anoutput module 88, the control unit 34 could store the information in thememory unit 56, such that a user could obtain the information bydownloading it to an auxiliary I/O device 90, such as a PDA, cell phoneor a laptop computer.

The above description of the embodiments should not be interpreted in alimiting manner since other variations, modifications and refinementsare possible within the spirit and scope of the present invention. Thescope of the invention is defined in the appended claims and theirequivalents.

1. A control system suitable for use with a bathing unit system having awater receptacle, said control system comprising: a) a heating modulehaving a body defining a passage through which water can flow; b) apower source for supplying power generated from solar energy to saidheating module, said power source including an energy storage memberadapted for establishing an electrical connection with a solar panel,said energy storage member being operative for storing energy collectedfrom the solar panel; c) a controller in communication with said heatingmodule and said power source, said controller being operative forcausing said power source to supply power to said heating module atleast in part based on: i) first information derived from a temperatureof water within the water receptacle; and ii) second information derivedfrom a condition associated to said power source.
 2. A control system asdefined in claim 1, wherein said energy storage member includes at leastone battery in communication with a battery charger for convertingenergy collected from the at least one solar panel into an electriccurrent to charge said at least one battery.
 3. A control system asdefined in claim 2, wherein said second information is indicative of avoltage associated to said at least one battery.
 4. A control system asdefined in claim 2, wherein said power source is a second power source,said control system further comprising a first power source capable ofsupplying power to said heating module.
 5. A control system as definedin claim 4, wherein said controller is operative for selecting one ofsaid first power source and said second power source to supply power tosaid heating module.
 6. A control system as defined in claim 5, whereinsaid controller is operative for selecting one of said first powersource and said second power source at least in part based onpre-programmed instructions.
 7. A control system as defined in claim 5,wherein said controller is operative for selecting one of said firstpower source and said second power source at least in part based on auser command.
 8. A control system as defined in claim 6, wherein saidcontroller is operative for selecting one of said first power source andsaid second power source at least in part based on a signal conveyingwhether the bathing unit system is in use.
 9. A control system asdefined in claim 5, further comprising an auxiliary controller incommunication with said controller and said second power source, saidcontroller being operative for causing said second power source tosupply power to said heating module through said auxiliary controller.10. A control system as defined in claim 4, wherein said heating moduleis a second heating module associated with said second power source,said control system further comprising a first heating module associatedwith said first power source, said first power source being adapted forsupplying power to said first heating module and said second powersource being adapted for supplying power to said second heating module.11. A control system as defined in claim 10, wherein said controller isoperative for selecting one of said first power source and said secondpower source for supplying power to a corresponding one of said firstheating module and said second heating module.
 12. A control system asdefined in claim 11, wherein said controller is operative for selectingone of said first power source and said second power source at least inpart based on pre-programmed instructions.
 13. A control system asdefined in claim 11, wherein said controller is operative for selectingone of said first power source and said second power source at least inpart based on a user command.
 14. A control system for a bathing unitsystem, said control system comprising: a) a first power source; b) asecond power source suitable for supplying power derived from solarenergy, said second power source including an energy storage memberadapted for establishing an electrical connection with a solar panel,said energy storage member being operative for storing energy collectedfrom the solar panel; c) a controller in communication with said firstpower source and said second power source, said controller beingoperative for selecting one of said first power source and said secondpower source for supplying power to a heating module.
 15. A controlsystem as defined in claim 14, wherein said energy storage memberincludes at least one battery in communication with a battery chargerfor converting energy collected from the at least one solar panel intoan electric current to charge said at least one battery.
 16. A controlsystem as defined in claim 15, wherein said battery charger includes aregulation circuit for regulating the electric current supplied to saidat least one battery.
 17. A control system as defined in claim 14,further comprising an auxiliary controller in communication with saidcontroller and said second power source, said controller being operativefor causing said second power source to supply power to said heatingmodule through said auxiliary controller.
 18. A control system asdefined in claim 14, wherein said controller is operative for selectingone of said first power source and said second power source at least inpart based on pre-programmed instructions.
 19. A control system asdefined in claim 14, wherein said controller is operative for selectingone of said first power source and said second power source at least inpart based on a user command.
 20. A control system as defined in claim14, wherein said controller is operative for selecting one of said firstpower source and said second power source at least in part based onwhether the bathing unit system is in use.
 21. A control system asdefined in claim 14, comprising a first heating module associated withsaid first power source, and a second heating module associated withsaid second power source, each of the first and second heating moduleshaving a body defining a passage through which water can flow.
 22. Acontrol system as defined in claim 21, wherein said controller isoperative for selecting one of said first power source and said secondpower source for supplying power to a corresponding one of said firstheating module and said second heating module.
 23. A control systemsuitable for use with a bathing unit system having a water receptacle,said control system comprising: a) heating means for heating water fromthe water receptacle; b) power source means for supplying powergenerated from solar energy to said heating means, said power sourcemeans including energy storage means adapted for establishing anelectrical connection with a solar panel, said energy storage meansbeing operative for storing energy collected from the solar panel; c)controller means for causing said power source means to supply power tosaid heating means at least in part based on: i) first informationderived from a temperature of water within at least one of the waterreceptacle and a heating module; and ii) second information derived froma condition associated to said power source means.